Envelope Imager 2.

5
SERVICE
MANUAL
Preliminary
Revised: 6-4-07
Part #: M-6012

RENA SYSTEMS INC.

136 Green Tree Road STE 140
Oaks, PA 19456-1069
Phone: (610) 650-9170
Fax: (610) 650-9171
E-Mail: support@renausa.com
Web Site: www.renausa.com
 SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN
OPERATING THE PRINTER.
BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL
CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY
WARNINGS, AND INSTRUCTIONS:
9 Keep hands, hair, and clothing clear of rollers and other moving parts.
9 Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure
machine mechanisms come to a stop.
9 Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
9 Use the power cord supplied with the machine and plug it into a properly grounded wall outlet located
near the machine and easily accessible. Failure to properly ground the machine can result in sever
personal injury and/or fire.
9 The power cord and wall plug is the primary means of disconnecting the machine for the power
supply.
9 DO NOT use an adapter plug on the line cord or wall outlet.
9 DO NOT remove the ground pin from the line cord.
9 DO NOT route the power cord over sharp edges or trapped between furniture.
9 Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
9 Make sure there is no strain on the power cord caused by jamming between the equipment, walls or
furniture.
9 DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified
service representative. Report any damage of covers to your service representative.
9 This machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.
9 To prevent overheating, do not cover the vent openings.
9 Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.

This manual is intended solely for the use and information of RENA Systems Inc., its designated
agents, customers, and their employees. The information in this guide was obtained from several
different sources that are deemed reliable by all industry standards. To the best of our
knowledge, that information is accurate in all respects. However, neither RENA Systems Inc. nor
any of its agents or employees shall be responsible for any inaccuracies contained herein.

The Envelope Imaging Company TM is a registered trademark of RENA Systems Inc.

Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation.
Windows 95 and Windows 98 are registered trademarks of Microsoft Corporation.
IBM is a registered trademark of International Business Machines.
All other trademarks are the property of their respective holders.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher
 TABLE OF CONTENTS

Table of Contents
SECTION 1 – Installation 1
Contents of Packaging 1
Unpacking the Printer 1
Attach the Side Guides to the Printer 2
Installing the Ink Cartridges 2
Connecting to Power 3
Connecting to the Computer 3
Installing the Printer Driver 3
Installing the BIOS Manager 4
SECTION 2 – Trouble Shooting 7
Power Problems 7
Interface Communication Problems 7
LCD Display Problems 8
Feeding Problems 8
Printing Problems 10
Print Placement Problems 12
Print Content Incorrect 13
Software Problems 13
Service Diagnostic Tests 13
SECTION 3 – Functional Operation 15
Sequence of Operation 15
The Printer Control Panel 16
Printer Driver Properties 18
Printing from Microsoft Word 22
Print Recovery after Jam 24
PC Board and Electrical Component Location 25
SECTION 4 – Adjustments 27
Carriage Assembly Timing Adjustment 28
Carriage Assembly Side Play Adjustment 29
Output Voltage Adjustment 30
Media Sensor Adjustment 31
Print Speed Adjustment 32
Brake Adjustment 33
SECTION 5 – Disassembly and Assembly 35
Tools Required 35
Basic Disassembly 35
Replacing Separator Tips 37
Service Disassembly Procedures 37
Operator Side Covers 37
Non Operator Side Covers 39
Feed Deck 40

i
TABLE OF CONTENTS

Replacing Belts, Drive Rollers, Shafts, and Clutch 41

Replacing Printheads and Transport Belts 41
Replacing Drive Motor, Motor Control PCB, Power Supply 44
SECTION 6 – Maintenance 45
The Inkjet Cartridge 45
Jams in the Printer 47
Replacing the Sheet Separators 47
Replacing the Feed Rollers 48
Cleaning 49
Appendices 51
Appendix A – Envelope Imager 2.5 Specifications 51
Appendix B – Supplies and Optional Hardware 52
Appendix C – Wiring Diagram 53

ii
 SECTION 1
INSTALLATION

Section 1 – Installation
Contents of Packaging
1. Printer
2. Power Cord
3. Parallel Cable
4. Software
5. 1 set of four Soft Metering Segments
6. Side Guides
7. Operator Manual

Unpacking the Printer

Tools required Standard #2 Phillips head screwdriver.

1. Remove accessories from feed area of printer.

2. Remove foam block from printhead area.

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SECTION 1
INSTALLATION

Attach the Side Guides to the Printer

1. Remove the two screws from the side guide
blocks.
2. Position the side guide screw holes so that
they align with the holes in the side guide
blocks.
3. Insert the screws removed in step 1 and
tighten them so that the guides are firmly
attached to the side guide blocks.

Install the Inkjet Cartridges

The Printer can be configured with 5 inkjet cartridges. The cartridges are installed as follows:
• Remove the inkjet cartridge from its
packaging, taking care not to touch the copper
contacts, the metal plate, or the gold
printhead. Remove the protective tape from
the printhead.
• The cartridges are held in place by a latch
lever mounted on the inkjet cartridge holder.
Release the lever by raising it vertical.
• With the cartridge’s printhead pointing down,
slide the cartridge into the holder and push
down and toward the contacts in the holder.

• Make sure the cartridge is seated in the holder

then close the latch lever to secure the
cartridge in the holder. Do not force the lever
into place. (See the diagram.)
• Repeat the above for the remaining cartridges.

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 SECTION 1
INSTALLATION

Connecting the Printer

Plugging in the Printer
Make sure that the main power switch of the Printer is in the OFF position.
1. Connect one end of the power cord to the rear
of the Printer in the corresponding receptacle.
2. Plug the other end into a 115-220 Volt AC,
50/60 Hz. Grounded outlet.

CAUTION
DO NOT USE AN ADAPTER PLUG OR
EXTENSION CORD TO CONNECT THE
PRINTER TO THE WALL RECEPTACLE.
DO NOT USE OUTLETS CONTROLLED
BY WALL SWITCHES.
DO NOT USE AN OUTLET THAT
SHARES THE SAME CIRCUIT WITH
LARGE ELECTRICAL MACHINES OR
APPLIANCES.

Connecting to the Computer

Plug the parallel printer cable from your computer
into the rear of the printer and latch the two locking
clips. The cable used to connect the Printer to the
computer must not exceed 6 feet long.
NOTE: The parallel port may be used for all
versions of Windows. The USB port is used only
for Windows ME, 2000, and XP.

Installing the Printer Driver

A dedicated printer driver is included with the Printer. It is installed on your computer and is used by your
applications whenever you are printing from the Printer. Follow the steps below to install the driver:
NOTE: The driver disk for the Printer should automatically open when installed. If it doe not
use the steps below. The driver is not installed as a standard windows driver.
1. If you have any applications running on your computer close them and restart the computer before
beginning the driver installation.
2. Install the CD in the CD drive and click on
START. Then click on RUN, then type the
following; D:\Setup.exe (where D is the CD drive)
Then click OK.
3. The “Add Printer Wizard (n.nn)” window will
open., click Next>..
4. Type in your Name and Company and click

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SECTION 1
INSTALLATION

Next>.
5. Select the printer port LPT1:. Then click Next>. The “Add Printer Wizard” will appear. Select
Envelope Imager 2.5, then click Next>.
NOTE: Each printer has a specific driver.
Select the Envelope Imager 2.5 driver.
6. The next screen allows you to “Name
Your Printer”. Unless you have another
printer of the same name on your system
or network ignore this step and click
Next>.
7. Click Finish to complete the installation.

Installing the BIOS Manager

The BIOS Manager is used to upgrade the BIOS in the I-30 and I-30v Printer.
To Install the BIOS manager on your computer do the following:
1. If you have any applications running on your computer
close them and restart the computer before beginning
the BIOS manager installation.
2. Install the CD in the CD drive and click on START.
Then click on RUN, then type the following;
D:\SetupPCLPrinterUitilities.exe (where D is the CD
drive) Then click OK.
3. Follow the directions on the screen to install the BIOS
manager software.
Using the BIOS manager
From time to time you may receive a new BIOS for the printer. When you do it will have to be loaded in
the flash ROM on the printer. This is where the BIOS manager comes in. First you will receive the new
BIOS either via e-mail or on a floppy disk. It will have to be loaded into the BIOS manager software.
1. Open Windows Explorer and click on
Program Files, then PCL Only Printer
Utilities. Save the BIOS file to this folder.
2. Connect the Printer to the computer and
turn the Printer ON.
3. Then in Start click on Programs, then the
“PCL Only Printer Utilities” program and
then click on “PCL Only BIOS
Manager.exe” to start the program.
4. The BIOS Manager window will open.
Click on the Open button, and select the
new BIOS from the list of BIOS. Then
click Open. This will return you to the

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 SECTION 1
INSTALLATION

BIOS Manager. Check to see that the green Line light is lit and then click on Install and the program
will install the new BIOS on the printer.

WARNING
DO NOT TURN OFF OR DISCONNECT THE PRINTER DURING THE DOWNLOAD
PROCESS. DOING SO WILL DAMAGE THE MAIN PROCESSOR PC BOARD.

5. The BIOS manager will install the new BIOS. When the downloading is completed click on Exit to
exit the program.

5
SECTION 1
INSTALLATION

Notes

6

Section 2 – Trouble Shooting
This section is arranged by first the condition that might occur, and then by possible
problems, their cause and recommended solutions.
Power Problems
CONDITION
Power is on, nothing happens. No power to printer
Interface Communication Problems
CONDITION
Printer does not respond to
software.
Printer not responding to
software
SECTION 2
TROUBLE SHOOTING
PROBLEM SOLUTION
Check that the power cord is plugged in.
Check that the power outlet is live.
Check the fuse in the main power switch.
Replace with a fuse of the same rating.
Check the fuses on the power supply PC Board.
(Requires disassembly)
Bad controller PC Board.
Bad power supply.
PROBLEM SOLUTION
Connection problems. Check that port is
communicating with printer by
using another parallel or USB
cable, replace cable.
If port cannot communicate using
another parallel or USB cable,
check printer.
If port cannot communicate using
another parallel or USB cable
and the printer is OK, check
parallel or USB port.
Check cable connection to see if
any of the pins are bent or
missing. If so replace cable.
Poor connection between printer Turn printer off and on again.
and computer
Check connections.
7
SECTION 2
TROUBLE SHOOTING

LCD Display Problems

CONDITION PROBLEM SOLUTION

No LCD display Power not on Turn power switch on. If still no

display see Power Problems

Contrast pot broken or Adjust pot or replace display PC

maladjusted Board.

Broken solder joint on contrast Repair or replace the display PC

pot Board.

LCD shows solid line of Power supply. Check voltages and inspect the
characters or garbage. power supply connections to the
processor PC Board.

Static electricity Turn printer off and then on.

LCD displays solid black line or Bad power supply Check all voltages
lines
No firmware (BIOS) Install firmware

Bad processor PC Board Replace processor PC Board

Feeding Problems
CONDITION PROBLEM SOLUTION

Intermittent feeding Feed ramp not used The feed ramp adds a slope to the stack
and helps feeding.

Side guides set improperly Loosen the side guides slightly.

Dirty feed rollers Clean the feed roller with distilled water
and a cloth. DO NOT use any solvents or
detergents as they may damage the feed
rollers.

Paper stuck together Fan media before placing it in printer

Bad or dirty sensor Clean sensor with compressed air or

replace it.

Uneven mail piece Tap inserts to front of envelopes and retry.

Multiple feeds Separator gap not set properly. Adjust separators to thickness of media.

Sensor bad or dirty Clean sensor with compressed air or

replace it.

Media stuck together. Fan media before feeding.

8
 SECTION 2
TROUBLE SHOOTING

CONDITION PROBLEM SOLUTION

Multiple feeds Side guides too close to media Push side guides away from media.
continued
Brake misadjusted. Adjust brake (see Section 4- Adjustments)

Failure to feed Side guides too close to media Readjust side guides

ENTER key not pressed. Instruct user on proper operation.

No power to printer. Check the power button is ON and that

the power cord is plugged in.

Feed gap too tight. Adjust separator to thickness of media

Feed gap too loose Adjust separator to thickness of media.

Material is out of specification. Maximum thickness is 1/4” or 0.125”

Motor on, feed rollers not turning. Press the ENTER key, check for broken
drive belt and replace, check for loose set
screws on drive pulley or belt drive roller
pulley.

Clutch not engaging. Replace Clutch.

Motor failure. Check motor circuit breaker or replace

motor.

No power See Power Problems in this Section.

Printhead adjustment too low. Adjust printhead height to accommodate

the media thickness.

Jams Paper path obstruction Clear jam and remove pieces remaining
under printhead.

Paper not loaded properly Instruct operator in proper loading of

media.

Feed ramp not used properly Set feed ramp

Separators improperly adjusted Adjust separators to thickness of media.

Media curled or bent. Uncurl media.

Bad or Dirty Sensor Clean or replace sensor.

9
SECTION 2
TROUBLE SHOOTING

CONDITION PROBLEM SOLUTION

Jams continued Worn separator tip. Replace separator tip.

Printhead adjusted too low. Raise printhead

Conveyor tape(s) under printhead Replace tapes.

broken.

Printing Problems
CONDITION PROBLEM SOLUTION

No printing: Media is blank after Sensor did not see the piece and Clean or replace the sensor as
going under printheads. send the signal to print to the PC required.
Board.

Clogged cartridges Clean and purge cartridges

Cartridge dried out Install new cartridge

Tape on printhead Remove tape

Cartridge not properly inserted Remove and reinsert cartridge

Cartridge empty Install new ink cartridge

Power supply voltage out of spec. Check voltages

Printhead holder Check flex circuit for tears

Printhead not positioned correctly Adjust printhead to print on

to print on media media

Print slanted or skewed Skew within specs. ± 2.5° from bottom edge of
material

Side guides not set properly Readjust

Printheads adjusted too high Reset or lower printheads

Line spacing not uniform Printheads not aligned properly Realign printheads

Gray print Ink cartridge almost dry Replace ink cartridge

Blurry print Envelope thickness adjustment Adjust media thickness knob to

incorrect lower printhead
Dirty printheads Clean printheads
Paper too porous or absorbent Use other paper
Printheads scratched when Replace printhead
cleaned

10

CONDITION PROBLEM
Blurry printing continued Printhead assembly not
synchronized
Printing light Printhead clogged or dirty
Resolution of output set too low
Running low on ink
Print streaking Envelope thickness set too low
Exit roller dirty
Printhead dirty
Non-uniform print quality Check voltage from power supply
Poor printhead connections
White lines/streaks in a line of Ink cartridge nozzle dirty
print
Cartridge not properly inserted
Cartridge was hit, shaken, or
dropped
Tap water was used to clean
cartridge and mineral deposits
have blocked the ink chamber
Wrongly directed or forceful
wiping have driven particles into
nozzles
Cartridge low on ink
Tape covering print nozzle or
vent holes
Printhead connections not set
Bad printhead drive card
Smeared ink Carriage too low
Coated paper preventing ink
absorption
High humidity slowing drying
time
SECTION 2
TROUBLE SHOOTING
SOLUTION
Adjust the carriage assembly
timing to ensure that the
cartridge assembly powers
smoothly and contacts the media
evenly on all corners
Purge and clean printheads
Reset to a higher resolution
Replace cartridge
Adjust media thickness
Clean exit roller with water
Clean printhead
Adjust to 14 VDC
Check that the flex circuit
connections are in place
Clean cartridge
Remove and reinsert cartridge
Replace Cartridge
Replace cartridge
Replace cartridge, Instruct
operator in proper cleaning
method
Replace cartridge
Remove tape
Check that flex circuit
connections are in place
Replace printhead drive card
Raise Carriage
Use fast-dry ink and/or allow
more time to dry after printing
Use fast-dry ink and/or lower dpi
resolution
11
SECTION 2
TROUBLE SHOOTING
Print Placement Problems
CONDITION PROBLEM
Print too close to leading or Size of media not set correctly in
trailing edge of media Layout
Bad or dirty sensor
Feed ramp not used properly
Printheads set incorrectly
Print too high or low on the Physical location of printhead
media does not match the layout
template
Address prints upside down on Layout and/or stock direction
media incorrect
Address too close to center of Chosen media size in layout is too
media small
The physical location of the
printheads do not match the
layout
Feed ramp not set properly
Address printing partially off Chosen media size in layout is too
media large
The physical location of the
printheads do not match the
layout
Feed ramp not set properly
12
SOLUTION
Check layout in layout for proper
size
Clean or replace sensor
Set feed ramp
Check the location and margins
in layout software. Check that
the piece on the layout screen
looks exactly the way you want
the piece to look. Remember
that there is a 1 5/16” space that
is always blank between Head 4
and 5 and the Head 1, 2, and 3
bank
Adjust the paper guides or
printheads
Use the “0” reference point in
the center of the scale to help
you align the print on the media
Change direction from Normal
to Inverted or Inverted to Normal
in the Properties of the Driver.
Set correct media width size in
layout
Check image on layout screen,
Adjust paper guide or printhead
Adjust feed ramp
Set correct size from in layout
Check image on layout screen,
Adjust paper guide or printhead
Adjust feed ramp
 SECTION 2
TROUBLE SHOOTING

Print Content Incorrect

CONDITION PROBLEM SOLUTION

Information being printed is Poor cable connections Check parallel cable:

wrong, incomplete, or garbage
Securely fastened at both ends
Cable does not exceed 6’ in
length
Printers internal parallel or USB
cable in good condition

Interface problem Check printer setup at computer

Corrupted database file Use another database file

Barcode does not print Wrong font selected If using a combined field
barcode choose USPS barcode
font

No zip code in database Put zip code field in database or

use another database
Barcode not enabled Enable barcode

Unwanted BOLD, Italic, or Turned on in layout Open layout and change type
Underlined type style

Not all addresses in database Only some of the addresses in Start new job and select entire
print database have been selected to database
print

Data is being lost Database problem Check the database program

Parallel or USB cable connection Reconnect

loose

Graphics or text have a white The graphic or text is set between Move the copy or adjusts the
line through them the junction of two printheads printhead

Software Problems
Refer to the manual for the application software being used.

Service Diagnostic Tests

TEST PRINT key
Press the TEST PRINT key to place the printer into the Test Printing mode. Press the ENTER key to
print a test sheet.
NOTE: Remove all media from the printer before performing these tests.
To access the Test Print mode press and hold the TEST PRINT key until “Service Menu” is displayed on
the printer control panel. You can use the + or – key to step through the test options.

13
SECTION 2
TROUBLE SHOOTING

Drive Speed Test

Press the ENTER key to start the main drive motor and display the belt speed in inches per second. Press
the ENTER key to stop the main drive motor. If the main drive motor does not start, the main drive motor
circuitry has a problem. No reading in inches per second indicates an encoder problem.
Motor Test
Press the ENTER key to start the main drive motor. Press the ENTER key to stop the main drive motor.
The main drive motor not starting indicates a problem in the main drive motor circuitry.
Clutch Test 1
Press the ENTER key to start the main drive motor and turn on the feed clutch. Press the ENTER key to
turn off the feed clutch. If the clutch does not engage there is a problem with the clutch circuitry.
Clutch Test 2
This test is designed to operate the clutch in an ON and OFF mode. Selecting this test and pressing
ENTER will cause the clutch to actuate and de-actuate in sequence.
Sensor Test
Press the ENTER key to display the state of the paper sensor. Uncovered displays when the sensor is
NOT covered. Covered displays when the sensor IS covered. Use a strip of paper inserted in the sensor
area to test its function. Failure to switch between the tow messages indicates a problem in the sensor
circuitry.
Power Supply Test
Press the ENTER key to display the voltage reading of the main power supply. The nominal reading is
between 13.5 and 14.5 volts. The power supply may need adjusting to bring the value within the nominal
range.
Encoder Test
Press the ENTER key to display the current encoder count reading. Move the exit roller. If the number
does not increase, this indicates an encoder failure.
Keyboard Test
Press the ENTER key to test the function of the individual keys on the keyboard. When a key is pressed
the display shows the key name. To exit this test you must power the printer OFF.
Head Lift Test
Turn the MEDIA THICKNESS knob to “0”. Then press the ENTER key to lower the printhead carriage
assembly. DOWN displays. Press the ENTER key to raise the printhead carriage assembly. UP displays.
Failure of the carriage to move up and down indicates a failure in the head lift circuitry or with the media
thickness control.
Ink Levels
The Ink Levels in each of the cartridges are displayed in this mode as a percentage. This will only display
properly if the operator resets the system when a new cartridge is installed.

14
 SECTION 3
FUNCTIONAL OPERATION

Section 3 – Functional Operation

Sequence of Operation
The user prepares the printer
1. Selects number and color of print cartridges required and installs cartridges in proper location.
2. Uses a single piece of media to set sheet separators.
3. Loads media and adjusts side guides to within 1/32” of media.
4. Stacks media in feeder and adjusts feed ramp.
5. User adjusts Media Thickness knob for proper printhead contact with media.
6. Turns printer on.

The user prepares the layout and creates a job

1. The user selects the database and opens the layout software such as Microsoft Word.
2. Creates a layout consisting of the variable data from the database using the merge function.
3. User then creates a layout using fixed information such as return address and adds graphics as
required.
4. User saves layouts.
5. User initiates the Print function through the File menu in the program.
6. User then selects through the printer driver properties menu if the job has and overlay or not.
7. User then clicks on the print button to print the job.

Printing the Job.

1. When the user sends the job to the printer and downloading is complete, the system sends a signal to
the interface board to turn on the main motor with the predetermined speed selected in the printer
driver.
2. This causes the ON LINE light illuminate on the ON LINE key and the drive motor starts to run
causing the media transport belts under the printheads to turn.
3. The printhead carriage is lowered by the servomotor to the preset adjustment which is controlled by the
Media Thickness knob.
4. The user then presses the ENTER key and the feed clutch turns causing the three sets of feed rollers to
turn and feed the media.
5. After the media travels 2.5-inches it covers the photosensor and makes it output go low. This turns off
the feed clutch and stops the feed rollers. The forwarding rollers that are driven by the transport belts
move the media forward to the printheads.
The 2.5-inch distance between the feeder and the photosensor paired with the clutch action creates a
2.5-inch gap between the mailing pieces. This gap allows the media to feed reliably and the variable
data sent by the PC to be positioned for printing.

15
SECTION 3
FUNCTIONAL OPERATION

Printing
The print engine consists of five stationary printheads and moving transport belts which position the media.
There are four circuit boars that control the printer. (See the end of this chapter for their description and
location.
Printer Functional Description
1. A photosensor in the path of the media between the feeder section and the printing section senses the
lead edge of the media and sends a signal to the print engine on the main processor board that the
mailing piece has arrived for printing. The feed clutch remains disengaged as long as a mailing piece
is in view of the photosensor.
2. When the mailing piece uncovers the sensor the clutch engages the feed rollers and the next piece of
media starts moving toward the printer section. At this time the print engine downloads the next
variable record from the PC and gets ready for printing.
3. This cycle repeats itself as long as there is media in the feeder.
4. Either the cycle stops when the feeder runs out of media, the operator stops the process, or there are no
records remain to be printed.

Printer Control Panel

1. ON LINE key – The indicator on this key lights when data is sent to the printer and
they are ready to begin printing. This key also turns the printer off line so that the
menu mode can be accessed..
2. - key – In the menu mode this key will scroll to the previous selection.

3. ENTER key – This key starts and stops the printing.

4. FAULT Indicator – This indicator lights when there is a problem with the printing
process.
5. RESET key – This key will reset the printer to its wait state.

6. + key – When the printer is in the menu mode this key will scroll to the next selection.

7. MENU key – This key causes the printer to enter the menu mode where several
operator functions can be accessed.
8. TEST PRINT key – Pressing this key will put the printer in the test mode and send a
sample copy to check the printer’s output.
9. OPERATOR DISPLAY – Indicates the printer’s status including menus and error
messages.
10. MEDIA THICKNESS – The knob on the right side of the control panel is used to
adjust the height of the print heads to compensate for different media thickness.

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 SECTION 3
FUNCTIONAL OPERATION

Printer Control Panel

When you first turn the printer ON, the light in the TEST PRINT key lights and the display becomes
active. At this point the printer is ready to print if it is connected to your computer.
The printer control panel keys can be used to access various functions that help the operator control the
printer. These functions and their operation are as follows:

ENTER key
The ENTER key is used to start the printer printing under production situations. When the printer is
placed in any of the menu modes, the ENTER key is used to choose the options available.

TEST PRINT key

Pressing the TEST PRINT key momentarily places the printer in the test print mode. The word “Working
“appears in the lower half of the display and after a short period of time the display changes to “Enter to
feed”. Pressing the ENTER key will start the printing process and print the test print. To stop the feeding
press, ENTER again.
To restore the printer to the normal ready mode press the ON LINE key to take the printer off line and then
press and hold the RESET key until the light on the TEST PRINT key blinks. The printer is then restored
to its normal ready state.
Pressing and holding the TEST PRINT key will cause the printer to enter the “Service Menu” where the
various functions of the printer can be tested. To exit the “Service Menu” turn the printer OFF, the ON
again. The service menu is primarily used by service to diagnose problems should they occur. You can use
the “+” or “-“ key to scroll through the menu. Pressing the ENTER key will test the function. To restore
the printer to its normal print mode, turn it OFF then ON.
To check the level of the ink cartridges when you enter the Service Menu press the “-“ key and the amount
of ink remaining will appear as a percentage in the lower half of the display window.

MENU key
The MENU key is used to access the special features built into the printer. The basic features are accessed
by momentarily pressing the MENU key. Use the “+” or “-“ keys to access the features. The features
available under this mode of operation are as follows:

Clear Batch Counter – Pressing the ENTER key will clear the number in the upper right hand corner
of the display. Resetting the counter is usually performed at the start of each job. Turning OFF the
printer will not reset this counter.
Purge First Piece – Turning the feature ON will cause the printer to sent one purge pattern on the first
piece. After the purge is completed the next piece will be have the first record of your database.
Turning the printer OFF will reset this to OFF.
Press Enter to Purge – The purging function is useful to clear the printhead nozzles when the
machine has been sitting idle for a period. To activate the purge, press the ENTER key and feed
media. To stop the purge press, ENTER again.
Address Recovery – In event of a jam in the printer you can recover up to 10 pieces by pressing the
MENU key, then stepping to the “Address Recovery”. Then press the ENTER key. The message
“Enter: Recover 1 Piece” will appear. Use the “+” key to select the number of pieces to reprint (1-10)
then press ENTER again to start the printing process. When the pieces are printed press the
ONLINE key and then the ENTER key to resume printing the job.
Print Enhancement – Pressing the “+” or “-“ key will bring this message up in the display. The print
enhancement feature is used when printing to ensure that the nozzles on the printhead stay open and

17
SECTION 3
FUNCTIONAL OPERATION

prevent the loss of the descender on letters such as “y” or “q” and accent marks that do not appear in
every address. Pressing the ENTER key will turn this function ON or OFF. The function will remain
as changed until the operator changes it again. Turning the printer ON and OFF will not affect the
setting.
NOTE: The Print Enhancement feature will time out after 100 seconds if no media is going through
the printer. Once media is being printed it will restart.
Installing New Printheads – The printer is capable of telling you when a printhead is running low of
ink. To use this feature press the MENU key momentarily. Then use the “+” or “-“ key to highlight
“Enter when head (n) is filled”. Press the ENTER key and install a new cartridge. Repeat for each
cartridge you install. When the ENTER key is pressed the display will change to “Head (n) has a new
cartridge”. To check the level of ink in the cartridges, Press and hold the TEST PRINT key until the
“Service Menu” appears. Use the “+” or “-“ key to scroll to the “Service Menu: Ink Levels,
100%100%100%”. This will show how much ink remains in the cartridge.
NOTE: This feature only works if the cartridges remain in the original head where they were
installed. If you swap the cartridges from one head to another, the levels will not be accurate.
There is a second set of menus available in the display. To activate them press and hold the MENU
key until the “Setup Menu” appears. You can step through these items with the “+” or “-“ key.
Total Count – The total count displayed is the total number of prints that have passed through the
printer. It is non-resettable.
BIOS Version – The version of the BIOS is displayed in this menu when the “+” key is pressed once.
From time to time it may be necessary to upgrade the BIOS in the printer. When this is done, the new
BIOS version can be checked in this manner.
Bulk Ink – This feature is not used on the printer. No provisions are made to install the larger
cartridges.
+ / - key
In the various menu modes these keys are used to step through the options.
ON LINE key
The printer automatically goes on line and the light in the ON LINE key lights when there is information
from the computer to print. Pressing the ON LINE key during the printing operation will take the printer
off line and stop the printing. To reset the printer to its ready state, turn it off line then press and hold the
RESET key until the light in the TEST PRINT key blinks.
RESET key
The RESET key is used to clear the printer memory and return it to the wait state. This key only functions
if the printer is off line.

Purge While Printing

To do the purge in the middle of a job, follow these steps:
Press ONLINE key to pause the current job.
Press the MENU key, then step to “Press Enter to Purge”.
Press ENTER key to start the purge and press the ENTER key again to stop purge.
Press ONLINE key and then the ENTER key to get back to normal printing.
Note. If paper jam occurs during the purge, after purge, you should use address recovery to get
back to normal printing. Otherwise you will lose records.

Printer Driver Properties

The printer driver describes to the printer how to print your job. It controls the operation of the printer and
allows you to send fixed and variable text and graphics to the printer. Within your data management

18
 SECTION 3
FUNCTIONAL OPERATION

software is a print function. In that print function is a properties button. It is through the properties that
you control the output of your printer. The following describes how to use the properties windows for the
printer driver to customize the output of your printer.
To start printing click on File, then Print. The Print window
will open. If you wish to print the job click on OK. If you
wish to use the special features built into the printer drivers.
Clicking on the Properties button will open the properties
window in Windows 95, 98, NT, or ME.

If you are using Windows 2000 or XP the window on

the right will open. Clicking on Advanced will open
the Options window. In the following illustrations the
windows for Windows 95, 98, NT, and ME will be on
the left. The windows for Windows 2000 and XP will
be on the right.

When the properties window opens you are presented with several tabs in Windows 95, 98, . The
following are standard windows printer driver functions and should be left at their defaults: Graphics,
Fonts, and Device Options. The Features and Print Heads tabs are used to setup, change, and adjust the
printer.

Features Tab
The Features Tab/ Advanced Options depending on the operating system is used to change the speed and
resolution of the Printer, to add a delay to the feed to provide separation between the pieces, and to print
and overlay with the job. The first feature is the Print Quality which has two settings. One for the

19
SECTION 3
FUNCTIONAL OPERATION

Resolution of the print quality and the second for the appropriate speed. Changing the resolution to a
higher number e.g. 200 DPI to 600 DPI will increase the quality of the image. When the resolution is
changed the Belt speed (IPS) is automatically changed to the optimum speed for the resolution selected.
You can, however change the speeds to a lower speed as follows:

Resolution Speeds available

150 DPI Low, Medium, Medium High,
and High
200 DPI Low, Medium, and Medium
High
300 DPI Low, and Medium
600 DPI Low

The Feed Delay can be used to put more space between the pieces as they are being printed. This will give
the first piece printed more time to dry before the next piece is printer. The adjustment range is in 0.1-
second increments. This feature works at all speeds.
The Overlay feature is used to save time printing when you are combining a database with fixed
information or graphics. The default is “No overlay”.

20
 SECTION 3
FUNCTIONAL OPERATION

To use the Overlay feature, first create a layout in an application such as Microsoft Word. Place all of the
fixed information and graphics on this layout. Open the layout and go to Print in the File menu. Click on
Features and then click on Overlay . Select “Contains overlay” from the box, then click on Apply and
OK.
Next click OK on the “Print” window. The overlay will down load and the printer will start running.
Now open the job that contains the variable data and using File then Print from the drop down menu open
the “Print” window for the application. Click on Properties then on the Features tab. Then click on the
drop down menu under Overlay and click on Previous job contains overlay. Click Apply, then OK.
When the Print window reappears, click OK to send the job to the printer. To start printing press the
ENTER key on the printer.
If you wish to print a second job using the same overlay, simply open that job and send it to the printer. If
the next job does not contain an overlay, then click on Properties in the “Print” window, select Overlay,
then No overlay. Click Apply, then OK.
To print the next job with a different overlay, Repeat the process for the first overlay.
NOTE: Turning the printer OFF, then ON will clear the overlay and the job.
Print Heads Tab
The purpose of the Print Heads tab is to permit slight (0.001-inch) adjustment to the position of the print
heads to each other. The adjustment is used to align the three printheads when printing graphics or type
that extends beyond the width of one printhead. Each head can be moved +/- 0.048-inch in 0.001-inch
increments.
If you want to move the printhead toward the lead edge of your layout then it should be moved in the “-“
direction. To move the head away from the lead edge move it in the “+” direction.
When the printer is turned off the changes that you make in this manner go back to the original settings.

Inverse Printing
The Paper tab contains one element that is used to reverse or invert the printing on the printer.
In normal operation the printing is read from the operator side of the printer. It is sometimes necessary to
turn the printing direction 180 degrees from the normal direction. This occurs when because of the layout
or the method of binding the media must be fed in the reverse direction.
Clicking on the paper tab and then on the paper source will permit you to reverse the printing direction 180
degrees.

21
SECTION 3
FUNCTIONAL OPERATION

The rest of the settings on this tab should be left as they are. Paper size is always “Max Print Area” and
Orentation is always “Portrait”. Do not change them.

Printing from Microsoft Word

If you are not using a specific program designed for mailing applications it is possible to print your mail
pieces using Microsoft Word. This section will cover how to layout a piece and to print from Microsoft
Word.
To begin open a new page and turn on the tool bar for Mail
Merge. Under Print select the Envelope Imager 2.5 as the
default printer. Go to Page Setup in the File menu. Set
all of the margins to “0”.
NOTE: The printer must be selected before you do the
setup so that the setting will be registered.

Next select the Page Size tab and Custom Page. The size
of the layout should be 2.5-inches high by the length of the
piece you are intending to print. In our example we have
selected the width of a # 10 envelop, 9.5-inches. The
orientation of the piece is always Portrait. The effective
printing area of the Envelope Imager 2.5 is 2.5-inches by
15-inches. When you have completed this step click OK.

22
 SECTION 3
FUNCTIONAL OPERATION

The next step is to create a text box so that you can position the address the proper distance from the lead
edge of the piece. Once the page layout is set, you might want to save it as a template for use later.
When you have completed the steps above the layout should look like the one below.

NOTE: When setting up a layout for the printer, be aware that the printheads are aligned in two
banks and these banks face each other. The minimum distance between printheads 1, 2, and 3 and
printheads 4 and 5 is 1-5/16-
inch. This in effect permits
you to print the return
address on heads 4 and 5 with
an indicia and the variable
address on heads 1, 2, and 3.
When printing in this manner
it is a good idea to use the
overlay feature for the fixed
information. The actual head
layout on a #10 envelope
appears at the right.

Click on Tools and then Mail Merge. The “Mail Merge Helper “ window will open. Click On Create,
then Envelopes. The “Microsoft Word” window
will open. Click on the Active Window button,
then click on the Get Data button. Next click on
Open data source. Locate the data file you intend
to use. In our example we are using a Microsoft
Excel file. Select the file and the “Microsoft
Excel” window opens select entire spreadsheet
and click OK.
Next click on Edit Main Document and then
click on Close.
Use the Mail Merge Tool Bar, click on Insert
Merge Field, and begin to build the layout
by inserting the address fields.

23
SECTION 3
FUNCTIONAL OPERATION

When you have

completed setting up the
layout, click on the Mail
Merge icon on the tool
bar and the “Merge”
window will open.
In the Merge to menu
there are several choices
for where how the data is
exported. The two that
concerns us is “New
Document” and
“Printer”. If you choose
“New Document” the
merge will be created in your word application with a separate record for each address. If you choose
“Printer”, the merge will send directly to the printer and each record will be printed.
The next selection is “Records to be merged”. You can select All or From:.
The last selection is “When merging records”. The default is “Don’t print blank lines when data fields are
empty.” This should be left checked.
Clicking on Merge will start the process of merging the documents.
If you chose to send the merge directly to the printer and the printer is connected to the computer and
turned ON, the printer will start. Pressing the ENTER key will start the printing process.
If you have a graphic or fixed text to be printed with the data, refer to the section on Overlays.

PC Board and Electrical Component Location

Non-Operator Side

24
 SECTION 3
FUNCTIONAL OPERATION

Rear View

Operator Side Left-hand Cover View

25
SECTION 3
FUNCTIONAL OPERATION

Non-Operator Right-hand View

26
 SECTION 4
ADJUSTMENTS

SECTION 4 – Adjustments

WARNING
THE ELECTRICAL ADJUSTMENTS ARE MADE
WITH THE MACHINE UNDER POWER. MAKE
SURE TO USE NON-METALLIC TOOLS WHEN
ADJUSTING POTENTIOMETERS ON PC BOARDS.

27
SECTION 4
ADJUSTMENTS

Carriage Assembly Timing Adjustment

REQUIREMENT: To ensure the carriage assembly lowers smoothly and contacts the
media evenly on all corners.
ADJUSTMENT:
1. Unplug the machine and remove the front left- 8. Check at the center of the top of the belt for
hand cover. (4 screws) at least 1/4"deflection.
2. Turn the MEDIA THICKNESS knob to “0”. 9. Rotate the large gear on the servo motor
3. Remove gear from potentiometer two hex counter clockwise until the carriage is in its
screws [1]. lowest position and the rollers on the heads
4. Remove servomotor mounting bracket four are touching the belts on the conveyor.
screws [2]. Do not disconnect the wires from 10. Turn the potentiometer clockwise, and then
the machine. turn counterclockwise approximately 2
5. Turn the two pulleys clockwise so that the degrees.
pins [3] are at the top of the upper slots. 11. Install the gear on the potentiometer shaft,
6. Install the belt and servo motor assembly align it with the gear on the servomotor and
using the four screws removed in step 4. tighten the two hex screws [1] to secure it.
7. Apply a downward pressure on the NOTE: It may be necessary to rotate
servomotor-mounting bracket and tighten the the servo motor gear to secure the second
four screws [2]. hex screw.
NOTE: Make sure that the carriage 12. Turn on the printer and press the STANDBY
assembly cams remain at the top of the top key. Check to see that the guide rollers on
slots. the heads contact the belts evenly as you turn
the MEDIA THICKNESS knob.
13. Replace the side cover.

28
 SECTION 4
ADJUSTMENTS

Carriage Assembly Side Play Adjustment

REQUIREMENT: To ensure the carriage assembly does not move from side to side
when printing.
ADJUSTMENT:
1. Unplug the printer and remove the front left-hand side cover.
2. Loosen the two nuts [1], then turn the hex head screws [2] to remove the side to side play in the
carriage assembly. The play should be less than .005 inches.
3. Tighten lock nuts.

29
SECTION 4
ADJUSTMENTS

Output Voltage Adjustment

REQUIREMENT: To provide proper output from power supply to machine.
ADJUSTMENT:
2. Adjust R14 (V1 ADJ) potentiometer [3] on
1. Remove the left-hand rear cover and connect the Power Supply module P/N 123-1313 to
voltmeter probe to GND [1] and TP3 [2] on obtain 14 VDC ± 0.1 V.
Interface PC Board P/N 97-500-30. Turn the 3. Turn the printer OFF, apply lacquer such
printer ON. as nail polish to the potentiometer, and
replace the cover.

INTERFACE PC BOARD POWER SUPPLY

MODULE

30
 SECTION 4
ADJUSTMENTS

Media Sensor Adjustment

REQUIREMENT: To assure that the media sensor senses the media.
ADJUSTMENT:

1. Remove the left-hand rear cover and connect 3. Adjust R20 potentiometer [3] to read 0.5
voltmeter probe to GND [1] and TP4 [2] on VDC maximum.
the Interface PC Board P/N 97-500-30.
4. Apply lacquer such as nail polish to the
2. Insert a BLACK media card over the sensor. potentiometer to prevent movement of the
Turn the printer ON. adjustment.

5. Turn the printer OFF and replace the cover.

INTERFACE PC BOARD

31
SECTION 4
ADJUSTMENTS

Print Speed Adjustment

REQUIREMENT: To provide the proper speed of the printer at each of the print
quality settings.
ADJUSTMENT:
1. With the printer connected to the computer, 5. Set the Hi-Speed pot. (R14) [4] on the Interface
remove the left-hand and right-hand rear covers PC Board to its middle position and adjust the
and the rear panel. Turn the printer ON. MAX SPD [5] potentiometer on the Speed
Control PC Board until the frequency reads
2. Set the potentiometers R1 [1], R6 [2], and R8
40KHz.
[3] on the Interface PC Board, P/N 97-500-
30EU to their center or middle positions. 6. Then adjust R14 [4] to obtain a frequency of
45.0KHz (75 ips). Feed one piece of media.
3. The CURRENT LIMIT [4], DECL [8], and
ACCEL [9] potentiometers on the Speed 7. Restart the job above, but set the speed at
Control PC Board P/N 123-1405 (MMXL05) or Medium High and adjust R11 [3] to obtain a
P/N 123-1651 (MMXL02) are pre set at the frequency of 36.0KHz (60 ips).
factory and should not require adjustment.
8. Repeat Step 7 again, but set the speed at
There is an arrowhead on the adjustment slot of
Medium and adjust R7 [2] to obtain a
the potentiometers to indicate direction.
frequency of 27.0KHz (45 ips).
⇑ ⇐ ⇐
9. Repeat Step 7 again, but set the speed at Low
4 8 9
and adjust R1 [1] to obtain a frequency of
The IRCOMP pot [7] is set at a different angle 13.2KHz (22 ips).Then exit the CONTROL
depending on the PC Board model. If the motor PANEL software and turn OFF the printer.
does not maintain set speed as the load changes,
10. Apply lacquer such as nail polish to the nine
gradually adjust the IR COMP pot clockwise. If the
potentiometers to prevent movement of the
motor oscillates, the IR COMP pot may be set too
adjustments and replace the covers.
high. Turn it counterclockwise to stabilize the
drive.
4. Hook up a frequency meter to GND and SIG 2
test point on Main Processor PCB. Open a job
and click on File, then Print. In the Properties
window select Features and then select
150DPI and High speed. Click Apply, then
OK. Then click OK to start the printer.

INTERFACE PC BOARD SPEED CONTROL PC BOARD

32
 SECTION 4
ADJUSTMENTS

Brake Adjustment
REQUIREMENT: To provide the proper tension on the front feed shaft brake
assembly for proper feeding of the media.
ADJUSTMENT:
1. Disconnect the Printer from the power source. 6. Start the Printer. Press the STANDBY key, then
the SELECT key to start the feed rollers.
2. Remove the left-hand cover, right-hand cover
Observe the reading on the meter, then turn the
and the rear closure.
brake tension adjustment screw [1] clockwise
3. Disconnect one side of the Motor Circuit until a 0.25 AMP increase is noted on the meter.
Breaker and connect a VOM capable of reading
7. Turn off the Printer, disconnect from the power
AMPS in series with the motor and circuit
source, reconnect the circuit breaker to the
breaker.
motor, and replace the covers.
4. Reconnect the printer to the power source and
turn it on.
5. Turn the brake tension adjusting screw [1]
counterclockwise at least 3 full turns.

33
SECTION 4
ADJUSTMENTS

Notes

34
 SECTION 5
DISASSEMBLY – ASSEMBLY

Section 5 – Disassembly – Assembly Procedures

Tools Required
#2 Phillips head screwdriver 3/32” Allen wrench

#1 Phillips head screwdriver 5/32” Allen wrench

Basic Disassembly
Turn off Power

Disconnect Power Cord

Disconnect Interface Cable

35
SECTION 5
DISASSEMBLY – ASSEMBLY

Removing the Side Guides

Remove four screws as shown at right.

Removing the Feed Ramp

Remove two screws as shown at right.

This part does not have to be removed in order

to remove the feed deck.

Removing the Print Cartridges

1. Lift the blue lever.
2. Remove the cartridge.
3. Close the lever.

36
 SECTION 5
DISASSEMBLY – ASSEMBLY

Replacing the Separator Tips.

1. Before replacing the separator tips, unplug
the printer.
2. Release the sheet separator locking lever on
the left side of the feeder.

3. Push down the black tab on the separator to

expose the screw.

4. Use a Phillips screwdriver and remove the screw holding the metal cover over the separator. Use the
tip of the screwdriver to pry the separator tip out of its holder.
5. Replace the separator tip, reinstall the metal cover and screw. Do not over tighten.

Service Disassembly Procedures

NOTE: The following disassembly should only be done by a qualified, trained service representative.
CAUTION: When touching electronic boards wear a wrist strap that is grounded.
OPERATOR SIDE COVERS
1. Remove two screws at the top of the left hand
operator side covers. Then remove the two
screws from the bottom of the cover.

2. Remove the cover. Do not pull it too far

away as the cable to the control panel could
be damaged.

37
SECTION 5
DISASSEMBLY – ASSEMBLY

3. Disconnect the control panel cable from the

PC Board. The printhead carriage drive
mechanism is behind this cover.

4. Continue disassembly by removing the two

screws at the top of the right hand operator’s
side cover. Then remove the two screws
from the bottom of the cover and remove the
cover.

5. Reassemble in reverse order.

A is Head Transport Mechanism under Left

Operator Side cover.

See Carriage Assembly Timing Adjustment in

Section 4- Adjustments.

B is Brake Tension Adjusting Screw under

Right Operator Side Cover.

See Brake Adjustment in Section 4 –

Adjustments.

38
 SECTION 5
DISASSEMBLY – ASSEMBLY

NON-OPERATOR SIDE COVERS

1. Remove the two screws at the top of the left
hand non-operator side cover. Then remove
the two screws from the bottom of the cover.
2. Remove the cover.
3. Remove the two screws at the top of the right
hand non-operator side cover. Then remove
the two screws from the bottom of the cover.
The Interface PC Board [A] is under this
cover.
4. Remove the cover. Do not pull it too far
away as the cable from the printer port is
connected to the Main Processor PC Board
[B]. Disconnect this cable from the PC Board
and set the cover aside.
5. The two PC Boards under these covers are
attached to the machine by four screws each.
Unplug the connectors and then remove the
screws to remove the PC Boards.

INTERFACE PC BOARD
1. CLUTCH
2. SPEED CONTROL
3. INTERLOCK – Safety Switch
4. CONV. – Conveyor Interface
5. CONTROLLER
6. MEDIA SENS.
7. 15VDC IN – Power input for
Interface PCB.

39
SECTION 5
DISASSEMBLY – ASSEMBLY

MAIN PROCESSOR PC BOARD

1. PARALLEL PORT
2. USB PORT
3. ENCODER
4. PRINTER DRIVER PC
BOARDS
5. POWER INPUT
6. OPERATOR PANEL
7. INTERFACE PC BOARD
CONNECTOR

FEED DECK
1. Remove the two side guides.
2. Remove both Left and Right Operator and
Non-Operator side covers.
3. Remove two screws from each side of the
printer, as shown at right.
4. Lift the metering assembly from the machine.
5. Remove the Interface and Main Processor PC
Boards.
6. Remove the three screws from each side of
the printer as shown at right. It is not
necessary to remove the rear guide assembly.
7. Lift out feed deck.
8. Reassemble in reverse order.

40
 SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING BELTS, DRIVE

ROLLERS, SHAFTS, AND CLUTCH
1. Refer to the instructions for removing the
Feed Deck.
2. Remove the Bearing Cap for each of the
roller shafts you wish to remove from the
machine.
3. Slide the roller shaft through the hole created
when the bearing cap was removed to release
the roller bearing from the opposite side cap.
Release the belts, then lift out the roller shaft
assembly.
4. Remove the roller from the shaft and replace.
NOTE: Refer to Section 6 – Maintenance
for removal of feed rollers without
disassembling machine.
5. Reassemble in reverse order, taking care to re
install the drive belts in their proper places.

REPLACING PRINTHEADS AND TRANSPORT BELTS

1. Remove both the Operator and Non-Operator
side covers and the Main Processor PC
Board.
2. Remove top cover by removing the two
screws that attach it to the frame and the two
springs.

3. Remove cover over printhead assembly by

removing the two Allen screws front and rear.

41
SECTION 5
DISASSEMBLY – ASSEMBLY

4. Remove the ribbon cable from each cartridge. Take care

to prevent damage to the ribbon cable or the connectors.

5. Remove the Allen screw holding the

printhead assembly to the bracket and remove
the printhead assembly.
6. Repeat for the above steps for the second
printhead assembly.

7. Continue disassembly by removing the

ground screw and ground wire from the
carriage assembly.
8. Then remove the four screws that attach the
carriage assembly to the raising mechanism
and remove the carriage assembly by lifting
out from rear of the carriage raising assembly.
9. Remove exit roller safety shield screws and
safety shield.

42
 SECTION 5
DISASSEMBLY – ASSEMBLY

10. Remove the two screws [A] on the non-

operator side and the single screw on the
operator side. Then remove the front cover
plate from the front of the unit.

11. Remove the two screws [B] from both sides

of the belt guide and allow it to hang.
12. Remove the two screws [C] from both sides
of the transport belt support plate. Then
remove the two bearing housings [D] from
each side of the machine. Disconnect the
encoder drive belt from the roller and remove
the rollers from the machine.

13. Remove the belt guide, then remove the

transport plate and belts from the front of the
machine.
14. Reassemble in reverse order making sure that
the encoder drive belt is in its proper place
before installing the bearing caps.
It is easier when reassembling, to install the belt
drive roller first, then the front exit roller. Next
install the support plate, and then the belts guide
assembly. Lastly install the front cover plate.

43
SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING DRIVE MOTOR, MOTOR CONTROL PC BOARD,AND POWER

SUPPLY
1. Remove operator right hand cover and non-
operator left hand cover.
2. Disconnect receptacle plug wiring and
remove the receptacle assembly by pressing
on the hold down clips and pushing the
assembly through the mounting hole.
3. Remove the four screws [A], two each side
from the rear cover plate and remove the rear
cover plate.
4. To remove the motor, remove the three Allen
screws [B] that attach it to the non-operator
side-frame and disconnect the wires from the.

5. To remove the Motor Speed Control PC

Board, disconnect the parallel printer cable
from the machine. Then disconnect the wires
going to the board. Rest the machine on the
non-operator’s side and remove the four
screws that attach the PC Board to the base of
the machine. Remove the PC Board.
6. To remove the Power Supply, disconnect the
parallel printer cable from the machine. Then
disconnect the wires going to the board. Rest
the machine on the non-operator’s side and
remove the four screws that attach the
assembly to the base of the machine. Remove
the Power Supply

44
 SECTION 6
MAINTENANCE

Section 6 - Maintenance

This section covers how to care for the ink cartridges, clear paper jams, replace the sheet separators, and
perform routing maintenance on the printer.

The Inkjet Cartridge

The inkjet cartridges must be replaced when out of ink, when print quality is poor, or when purging and
cleaning have not helped the image quality.
The Approximate life of the HP 51645A Inkjet cartridges based on three lines of 20 characters at 10-point
size per address is:
High Quality 50,000 addresses
Standard Quality 100,000 addresses
Draft Quality 200,000 addresses

NOTE: These figures can vary depending on the font selected.

To Replace the Inkjet Cartridge:
• Remove the used cartridge from the cartridge holder by raising the latch lever to release the
cartridge, then pull the cartridge up and out of the holder.
• Remove the new inkjet cartridge from its packaging, taking care not to touch the copper contacts,
the metal plate, or the gold printhead. Remove the protective tape from the printhead.
• The cartridges are held in place by a lever mounted on the inkjet cartridge holder. Release the lever
by raising it vertical.
• With the cartridge’s printhead pointing down, slide the cartridge into the holder and push down and
toward the contacts in the holder.
• Make sure the cartridge is seated in the holder then close the lever to secure the cartridge in the
holder. Do not force the lever into place.
• Repeat the above for the remaining cartridges.

CAUTION
NEVER SHAKE, DROP, OR HIT THE CARTRIDGE AGAINST THE PALM OF YOUR HAND
OR ANY OTHER HARD SURFACE. SHAKING THE PRINT CARTRIDGE DOES NOT “MIX”
THE INK AND HITTING THE CARTRIDGE AGAINST A HARD SURFACE DOES NOT
CLEAR THE NOZZLES BOTH OF THESE ACTIONS ACTUALLY HURT THE PRINT
QUALITY BECAUSE THEY ALLOW BUBBLES TO FORM NEAR THE INK FIRING
CHAMBERS. THESE BUBBLES PREVENT THE NOZZLES FROM FIRING CAUSING
WHITE STREAKS IN THE PRINT IMAGE.

45
SECTION 6
MAINTENANCE

Storage
Short-term storage is defined as less than 2 days or less than 1 day in a hot and dry environment. Long-
term storage is defined as more than 2 days or more than 1 day in a hot and dry environment.
Short-term Storage
Leave the cartridge in the Printer for short periods of time, 1 day or less.
The next time that the Printer is used, the printhead may have to be cleaned and purged
Long-term Storage
Keep the printhead in an area that is relatively free of dust and paper particles that is not too dry
Place the cartridges in a Tupperware container with a damp sponge or towel to maintain
humidity and prevent the printhead from drying out.
When the cartridges are ready to be used again, the printhead will need to be cleaned.
Disposal
The cartridge may be disposed of in a normal manner.
If there should be an ink spill, use soap and water to clean up any problem areas. Abrasive soap works
well to get the ink off hands.

Cleaning the Printhead

To maintain good print quality it is important that the printheads are kept clean. During the printing
process ink spray, paper fibers, and dust can cause a build-up on the printheads. This build-up will
eventually degrade the print quality. If you begin to notice problems with the quality of the print, or to just
prevent a build-up from occurring with the printhead with a wet fiberless cloth.
Cloth should be: Cloth should not be:
D Soft U Abrasive
D Fiberless U Made of small fibers
D Moist with Water (Distilled is best but tap U Dry or containing chemical additives
works)

Wipe slowly across the long-axis with the

printhead facing down (as shown). Do not apply
excessive force, as this could scratch the nozzle
area.

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 SECTION 6
MAINTENANCE

Purging the Nozzles

If the printhead sits inactive for a period of time, ink may dry in the nozzles. Printing may not remove
these “ink plugs” from the nozzles. White streaks will then show up in the printed text or graphic. In order
to obtain better print quality, these ink plugs need to be forced out or purged. A Purge routine is built into
the Printer. It can be accessed from the LCD panel on the Printer from the MENU key. If this does not
solve the problem then proceed as follows:
1. Wipe the printhead with a wet cloth as described in "Cleaning the Printhead" above.
2. Perform the Purge routine from the Printer by pressing the MENU key momentarily and then the +
key. Load media and press the ENTER key to purge. Repeat if necessary.
3. Wipe the printhead again with a moist cloth.
NOTE: For more information refer to the Troubleshooting Print Heads in Section 5 – Trouble
Shooting Guide.

Jams in the Printer

If a jam occurs, STOP the Printer. Up to 10 missed addresses can be recovered at the printer control panel.
(See Section 3 – Functional Operation “Print Recovery After Jam.
Some possible reasons for jamming are:
1. Feeding more than one piece of media.
2. Damaged media, such a dog-eared (turn down corners).
3. Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements for
automated feeding is acceptable in the Printer.
4. Envelopes that are caught under the flap of another envelope or stuck to one another may cause
jamming.
Removing Jammed Media
1. It may be necessary to move one or more of the printheads to gain access to the jammed media. Take
care in removing jammed media to prevent damage to the print heads. All pieces of the jammed media
must be removed from the feed path.
2. Follow the instructions in Section 3 – Functional Operation “Print Recovery After Jam”.

Replacing the Sheet Separators

The sheet separators insure separation of the pieces as they are being fed. The do wear and must be
replaced from time to time. If you experience double sheet feeding and can not adjust the separators to
prevent it, they should be replaced. Replacement of the sheet separators is not difficult. Just follow the
steps below:
1. Turn off the printer and unplug it from the power
source.
2. Release the separator-locking lever and move the
paper side guides to their maximum open position.
3. Lower the separators so that they touch the feed roller.
4. Remove the screw [A] and the separator support [B.]
Then remove the separator [C] by prying it out of the
holder.
5. Install a new separator in place and replace the
separator support and screw.

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SECTION 6
MAINTENANCE

Replacing the Feed Rollers

To replace the feed rollers on the printer follow the steps below:
1. Before removing the feed roller access plate, unplug the power to the printer.
2. Using a Phillips screwdriver, remove the
four screws from the feed roller access
plate.

3. Remove the feed roller access plate.

4. Rotate the feed roller shaft so that the

screws are face up and use a 3/32-inch
Allen wrench to remove the two button
head cap screws. This will permit you to
remove one half of the feed roller. Rotate
the shaft until the two screws holding the
second half of the feed roller in place are
accessible. Remove those screws also.
Install the feed roller half and replace the
screws. Rotate the shaft, replace the second
feed roller half, and fasten with the
remaining screws.
5. Replace the feed roller access plate and
fasten with the four Phillips screws.

48
 SECTION 6
MAINTENANCE

Cleaning
The Printer

WARNING
THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED
REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING
ANY MAINTENANCE DISCONNECT THE MACHINE FROM ITS POWER SOURCE!

The Printer must be cleaned regularly of accumulated paper dust and ink. Depending on the types of media
that are run, paper dust may accumulate within the printer and on the transport. To clean the printer,
unplug it from the power receptacle and remove the covers.
The internal areas are best cleaned with a vacuum that has a soft brush attachment to help loosen the dust
particles. Take care not to damage the PC Boards or electrical wiring.
The exterior of the machine may be cleaned with any standard household cleaner which is non-abrasive and
does not contain plastic harming solvents.

CAUTION
NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE
PRINTER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS. ALWAYS
DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE
CLEANED.

Feed Rollers and Forwarding Rollers

The feed and forwarding rollers can become glazed with paper lint and ink from the media. They should be
regularly cleaned with a mild abrasive household cleaner on a damp cloth.

Avoid using solvents on the rubber rollers.

Cleaning the Media Sensor

Periodically check the media sensor located in the print carriage area of the printer section. The sensor
should be clean and free of accumulated paper dust. Use a vacuum with a soft brush attachment or dry
compressed air to remove the dust.

49
SECTION 6
MAINTENANCE

Notes

50
 APPENDIX A

Appendix A – Envelope Imager 2.5 Specifications

PRINT TECHNOLOGY Inkjet, Five HP 51645A High Capacity Inkjet Cartridges
ADDRESS SPEED Up to 22,000/hr - #10 Envelopes
PRINT QUALITY High Quality 600 x 600 dpi
(Dots Per Inch) Standard Quality 600 x 300 dpi
Letter Quality 600 x 200 dpi
Draft Quality 600 x 150 dpi
IMAGE AREA 2-1/2-inches X 15 inches
PRINT ORENTATION Normal and Reverse
INK MONITOR Via Display
FONTS All TrueType fonts available on PC
GRAPHICS, LOGOS, AND Allows printing of graphics, logos, and barcodes
BARCODES
MATERIAL SIZE Length – 5” to 15”
Width – 3” to 13.5”
MATERIAL THICKNESS Up to 1/4”
FEEDER CAPACITY: Up to 500 #10 envelopes
MEMORY 12 MB
PRINT COLORS Standard and Versatile Black, Red, Blue, Green, and Yellow
INK Water based may require drying assistance for coated stock
SOFTWARE WindowsTM Printer Drivers for WindowsTM 95, 98, 2000, NT, ME, and
XP
DIAGNOSTICS Built into firmware
FIRMWARE UPDATE Via PC interface in flash proms.
PC INTERFACE Parallel and USB
COUNTERS One operator resettable job counter, one permanent lifetime counter
DUTY CYCLE 51 million addresses total or 850,000 per month over a 5-year life cycle.
DIMENSIONS 11.5” H x 19.56” L x 20” W (292.1 mm H x 496.8 mm L x 508 mm W)
WEIGHT 69 lbs. (31.4 kg.)
ELECTRICAL 115VAC or 240VAC, 50/60 Hz
OPTIONS HP Versatile fast dry Black, and Red, Blue, Green, or Yellow,
Conveyor/Stacker

All Specifications Subject To Change Without Notice

51
APPENDIX B

Appendix B – Supplies and Optional Hardware

The following supply items and optional hardware are available from your RENA
Systems Dealer:
Supplies
Black Inkjet Cartridge HP 51645A
Fast Drying Black Inkjet Cartridge HP 6195A
Yellow Inkjet Cartridge HPC6173A
Red Inkjet Cartridge HPC6168A
Green Inkjet Cartridge HPC6169A
Blue Inkjet Cartridge HPC6170A
Versatile Black HPC8842A

Optional Hardware
Conveyor / Stacker Available
Drop Tray

52
Copyright © 2007 Rena Systems Inc.
Oaks, PA 19456-1069
02/27/2007
300-AJ1000PUS Rev A.